Replace Both Cylinder Head Covers Opel Vectra C

Important: Extreme cleanliness is important when working on the fuel system, since even minute dirt particles can cause engine or fuel system problems. Open fuel connections must be sealed with suitable sealing plugs from the Opel parts catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are determined for one-off use.

Remove

1. 1. Remove intake manifold upper part
2. 2. Remove 2 high pressure line brackets (1) • Remove bolt • Unscrew nut

3. 3. Remove 6 high pressure lines from pressure reservoir to injectors (1 and 2) • Unscrew 12x lock nut

Note. Close off any open fuel connections with suitable stoppers

4. 4. Remove high pressure line from high pressure pump to pressure reservoir (1) • Unscrew 2x union nut

Note. Close off any open fuel connections with suitable stoppers

5. 5. Unscrew cap of coolant compensation tank
6. 6. Raise vehicle by its entire height
7. 7. On lower engine compartment cover, open right-hand service flap • Unscrew 3x bolt
8. 8. Drain coolant • Place collecting basin underneath. • Open drain bolt (arrow) • Close drain bolt

9. 9. On lower engine compartment cover, close right-hand service flap • Tighten 3x bolt
10. 10. Loosen catalytic converter support (1) • Release 2 nuts

11. 11. Lower vehicle by its entire height
12. 12. Unclip engine wiring harness and lay aside
13. 13. Detach 4 coolant hoses (1) from coolant pipe • Release 4x clamp
14. 14. Detach 2 coolant hoses (3) from coolant compensation tank • Release 2x clamp • Take coolant compensation tank (2) out of bracket and lay aside – Disconnect fluid level display wiring harness plug

15. 15. Detach front exhaust pipe (1) from turbocharger • Unscrew 3x nut • Remove gasket.

16. 16. Detach coolant pipe (1) from cylinder head • Unscrew 2 bolts (2 and 4)
17. 17. Loosen and detach 2 coolant pipe brackets (3) from coolant pipe • Remove bolt • Unscrew nut
18. 18. Release coolant pipe (1) from cylinder block • Loosen bolt

Note. Loosen bolt with suitable tool (2)

19. 19. Remove engine cover bracket (2) • Unscrew 2x bolt
20. 20. Detach camshaft housing vent hose (1) • Unclip wiring harness • Release clamp

21. 21. Unclip 2x wiring harness plug • Set wiring harness to one side
22. 22. Detach 6 injector rubber seals (1) from cylinder head cover, cylinders 1, 3 and 5 • Unscrew 12x bolt
23. 23. Remove fuel temperature sensor fuel line (2) • Detach hose – Release clamp • Unscrew banjo bolt • Remove bolt

24. 24. Remove cylinder head cover for cylinders 1, 3 and 5 (1) • Unscrew 12x bolt

25. 25. Detach wiring harness bracket from cylinder head cover, cylinders 1, 3 and 5 • Unscrew 2x bolt
26. 26. Remove fuel hose (1) • Release 2x clamp
27. 27. Detach 3 injector rubber seals (2) from cylinder head cover, cylinders 2, 4 and 6 • Unscrew 6x bolt

28. 28. Remove intake camshaft for cylinders 2, 4 and 6 (3) • Remove engine cover bracket (2) – Unscrew nut • Detach camshaft housing vent hose (1) – Release clamp • Unscrew 12x bolt

29. 29. Detach wiring harness bracket from cylinder head cover, cylinders 2, 4 and 6 • Unscrew 2x bolt
30. 30. Detach oil filler port from cylinder head cover, cylinders 2, 4 and 6 • Unscrew 2x bolt – Remove Seal ring
31. 31. Detach switchover valve solenoid valve • Remove bolt
32. 32. Detach 3 injector rubber seals • Unscrew 6x bolt

Install

33. 33. Attach 3 injector rubber seals • Tighten 6x bolt 10 Nm
34. 34. Attach switchover valve solenoid valve • Tighten bolt
35. 35. Attach oil filler port to cylinder head cover, cylinders 2, 4 and 6 • Replace seal ring • Tighten 2x bolt
36. 36. Attach wiring harness bracket to cylinder head cover, cylinders 2, 4 and 6 • Tighten 2x bolt
37. 37. Clean sealing surfaces.
38. 38. Install cylinder head cover, cylinders 2, 4 and 6 • Replace gasket • Apply sealant (grey) to camshaft housing – Bead thickness 2 to 4 mm – Measurement I = 20 mm – Measurement II = 10 mm • Tighten 12x bolt 9 Nm • Install engine cover bracket – Tighten bolt • Attach camshaft housing vent hose – Fasten clamp

Note. Follow tightening sequence (1-12)

39. 39. Attach 3 injector rubber seals to cylinder head cover, cylinders 2, 4 and 6 • Tighten 6x bolt 10 Nm
40. 40. Install fuel hose • Secure 2x clamp
41. 41. Attach wiring harness bracket to cylinder head cover, cylinders 1, 3 and 5 • Tighten 2x bolt
42. 42. Clean sealing surfaces. • Sealing surface between camshaft housing and cylinder head cover
43. 43. Install cylinder head cover, cylinders 1, 3 and 5 • Replace gasket • Apply sealant (grey) to camshaft housing – Bead thickness 2 to 4 mm – Measurement I = 20 mm – Measurement II = 10 mm • Tighten 12x bolt 9 Nm

Note. Follow tightening sequence (1-12)

44. 44. Attach 6 rubber seals to cylinder head cover, cylinders 1, 3 and 5 • Tighten 12x bolt 10 Nm
45. 45. Install fuel line for fuel temperature sensor • Attach hose – Fasten clamp • Tighten banjo bolt – Replace gasket • Tighten bolt
46. 46. Clip in 2x wiring plug
47. 47. Attach camshaft housing vent hose • Attach wiring harness • Fasten clamp
48. 48. Install engine cover bracket • Tighten 2x bolt
49. 49. Fasten coolant pipe to cylinder block • Tighten bolt

Note. Tighten bolt with suitable tool

50. 50. Attach 2 coolant pipe brackets to coolant pipe • Tighten bolt • Tighten nuts
51. 51. Fasten coolant pipe to cylinder head • Tighten 2x bolt
52. 52. Attach front exhaust pipe to turbocharger • Replace gasket • Tighten 3 new nuts 23 Nm
53. 53. Attach 2 coolant hoses to coolant compensation tank • Secure 2x clamp • Insert coolant compensation tank in bracket – Connect fluid level display wiring harness plug
54. 54. Attach 4 coolant hoses to coolant pipe • Secure 4x clamp
55. 55. Clip in engine wiring harness
56. 56. Raise vehicle by its entire height
57. 57. Fasten support for catalytic converter • Tighten 2x bolts 28 Nm
58. 58. Lower vehicle by its entire height
59. 59. Install high pressure pump high pressure line to pressure reservoir • Tighten 2x lock nut 35 Nm

Note. Unscrew closure plugs

60. 60. Install 6 high pressure lines from pressure reservoir to injectors • Tighten 12x lock nut 30 Nm

Note. Unscrew closure plugs

61. 61. Install 2 high pressure line brackets • Tighten bolt 21 Nm • Tighten nuts
62. 62. Install intake manifold upper part
63. 63. Top up and bleed cooling system